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BMS HIL TEST SYSTEM

Real-time battery pack simulation

The BMS Hardware-in-the-Loop (HIL) Test System is a high performance platform providing all necessary input signals used for battery pack simulation. A real-time operating system executes complex cell and pack models commonly used for BMS algorithm development and firmware regression testing.

The Battery Management Systems (BMS) Hardware-in-the-Loop (HIL) Test System provides a safe and efficient method for engineers to test BMS algorithms and system performance during the early stages of development for applications such as:

Electric Vehicles/Plug-in HEVs

High Power UPS/Grid Energy Storage Systems

General Purpose Multi-cell Battery Stacks

Bloomy has designed a modular and configurable platform to accommodate the variety of battery input signals such as cell counts, sensors, IO, and communications required to simulate a BMS test atmosphere. Depending on the channel count, systems can range from a mobile industrial enclosure with high voltage safety to a desktop unit. The system software is a customized application built on the National Instruments VeriStand real-time test software environment, providing methods for configuring system models and test environment.

Trying to validate a BMS and perform environmental testing?

The BMS HIL Test System is a modular platform, providing a unique configuration to test individual BMS devices and functionality.

The BMS HIL Test System is the ideal platform to use when developing and testing a real-time embedded controller, benefits include:

Provides a safe and efficient method of simulating a high voltage battery

Implements irregular and dangerous physical battery conditions

Improves quality of testing with repeatable stimulus

Reduces test duration and cost by not using physical batteries

Shortens development process through executing known test scenarios

The following specifications are standard. Systems can be customized to accommodate your requirements.

Cell Channel Simulation

Number of Channels

12 / module

Max number of Modules

20 (240 channels @ 4.2V)

Channel Type

Sink and Source

Voltage Range per cell

0.0 to 5.0 V

Voltage Resolution

0.1 mV

Voltage Accuracy (Requires Remote Sense)

±3 mV

Balancing Current Range*

± 500.0 mA; output derates linearly under 2 V

Current Resolution

0.1 mA

Current Accuracy

±4 mA

Current Limiting Accuracy

±10 mA

Common mode isolation

1000 VDC CH-TO-CH, CH-TO-GND

Cell Channel Readback

Voltage Resolution

0.1 mV

Voltage Accuracy

±3 mV

Current Resolution

0.1 mA

Current Accuracy

±4 mA

Temperature Sensor Simulation

Typical Signal Type*

Resistance (Thermistor / RTD)

Number of Channels

12 / module

Range

10Ω to 500 kΩ

Resolution

1Ω

Accuracy

1%

Additional Signal Types

Analog voltage (± 10V)

Analog current (0 – 40mA)

Current Sensor Simulation

Typical Signal Type

Analog voltage

Number of Channels

2 channel

Range

± 10V

Resolution

16 bit

Accuracy

± 0.5%

Additional Signal Types

High accuracy (±2V) analog signals

CAN communications

BMS Bus Voltage Simulation

Number of Channels

2 channel

Voltage Range*

0 to 60V

Current Range*

0 to 20A

Power Range

850W

Communication Protocols

Standard Protocol

High-Speed CAN

Number of Ports

2

Baud Rate

40 kbits/s to 1Mbit/s

Additional Protocols

LIN, SPI, RS232, Modbus

Pack Voltage Simulation

Number of Channels

1 channel

Voltage Range*

up to 1000VDC

Current Range*

1.5ADC

Programming Accuracy

± 0.075% of full scale

BMS Control IO

Number of Channels

24 input / 24 output

Voltage Range

0 to 60V

Voltage Low Logic Level

1VDC

Voltage High Logic Level

Min: 3.2VDC, Max: 60VDC

Common mode isolation

60V channel-to-channel

* Do you have special requirements for cell, bus, or pack voltage or current; isolation , temperature simulation, or communications? Contact us.

Bloomy use the latest versions of the National Instruments VeriStand and LabVIEW development environments to customize the application software based on final system hardware. Because all BMS units are unique, Bloomy has developed system level components to facilitate platform scalability and supportability to reduce software customization. Major application features:

Graphical User interface: to ensure you get the most out of the system, a customized interface is provided to view full system status and perform all system control, test, report viewing, and configuration.

Videos

Testimonial

Major BMS firmware releases can now be rolled out within one week with good confidence of success, whereas similar projects in the past used to take well over a month, and with substantially less confidence.